Metal-reenforced fiber board



July 15, 1930. w. F. HAYES 1,770,521

METAL REENF'ORCED FrBEH BOARD Filed Oct. 1, 1928 gwoeml oz Patented July 15, 1930 UNITED STATES PATENT OFFICE WILLIAM F. HAYES, OF DETROIT, MICHIGAN, ASSIGNOR T GAGNIER FIBRE PRODUCTS COMPANY, OF DETROIT, MICHIGAN, A CORPORATION OF MICHIGAN METAL-REENFORCED FIBER BOARD Application filed October 1, 1928.

This invention relates to an improved metal reenforced fiber board. The improved board may be used in the construct-ion of containers and portable articles of various kinds, and is particularly well adapted as a covering for walls and similar surfaces.

Said board has also been found to be particularly useful in the manufacture of finishing panels for the inside surfaces of automobile bodies, such as the doors, etc. The invention may be applied in numerous other situations Where a relatively inexpensive fiber board of great strength, but of light weight, is desired.

This application presents an improvement on the board disclosed in my copending application, Serial Number 117 ,480. In the commercialization of the board of the application just referred to difficulties arose that have been entirely overcome by the board of this application. In the first place, in my prior application a board including a composition body was proposed. It was found in practice that in die cutting such a board the composition body had a tendency to gum up the knives. Difficulties also developed in securing a plastic body of an even thickness at all points thereof. Accordingly, a board frequently resulted that varied in thickness at different points thereof. I have discovered that it is possible to avoid the use of a plastic layer of substantial thickness between the outer surface layers, and I have found that it is possible by properly selecting the wire fabric and cloth, and by properly selecting the fibrous material that-is to form the surface layers of the finished proudct, that the wire fabric and the surface layers may be intimately combined to form a homogeneous structure without the necessity for the addition of relatively large quantities of initially plastic or cementitious material.

In the manufacture of the board disclosed in my prior application just referred to it was found that the outer surface protecting layers of fibrous material absorbed moisture to varying degrees, depending upon climatic conditions, causing a blistering and a warping of the product. I have found that in the improved board, that forms the subject of Serial No. 309,535.

this application, this objection can be avoided by applying to the outer surface of the completed oard a substantially water-proof coating that serves to fill the pores in the exterior surface of said board and prevent access of moisture to the interior thereof. Essentially, the improved board of this application consists of a metal cloth or fabric c0mbined with fibrous material, such as paper, in such manner that the paper is pressed in the interstices of the cloth or fabric and in which the layers of fibrous material are firmly cemented to the cloth and to each other to form a homogeneous structure, the board thus produced being treated externally so as to substantially seal all the pores in the exposed surface thereof. I have found that laminated boards including a metal cloth or fabric, com bined with fibrous materials, have a tendency to assume a warped or curved form. It is extremely desirable, in fact, essential, in the production of a board such as disclosed in this application, that the product exhibit no such tendency. Laminated board manufactured in accordance with the disclosure of this application will lie perfectly flat and can, in view of this fact, be shipped in bundles that occupy relatively small space.

The primary object of this invention is to provide a metal-reenforced fibrous board that exhibits great strength, that is of extremely light weight compared with boards having a strength commensurate with the board of this applicati n. that is exceedingly durable, that is flexible so that it can readily be bent to curved or broken surfaces if desired, or even doubled, as at the edges to provide a finished edge, without weakening the product and that can be tacked, or even sewed, without tearing.

A further object of the invention-is to provide a metal-reenforced fibrous board that has a natural tendency to remain in flat condition and in which the constituent layers will remain in firm adherent contact at all points of the board when it is put into service and exposed to moisture or similar conditions.

A further object of the invention is to provide a met-al-reenforced fibrous board that is inherently capable of being corrugated or ditions of service. The wire cloth or fabric embossed to provide an ornamental appearance when it is put into use without substantially or materially weakening the board.

A further object of the invention is to provide a board that may be corrugated to add to the rigidity thereof, without in any manner rendering the board otherwise unsuited for use.

A further object of the invention is to provide a steel-fabric reenforced fiber board in which the reenforcement is intimately united with and pressed into the fiber at substantially all points and provided with relatively hard fibrous outer surfaces.

A still further object of the invention is to provide a steel fabric reenforced fiber board provided with a surface covering or coverings of fabric material firmly united to the board at all points providing a unitary flexible covered laminated board that may readily be put to a use in which initially separate foundation material and a separate outer covering or separate coverings are now put.

Further objects of the invention will appear as a description thereof proceeds with reference to the accompanying drawings in which:

Fig. 1 is a plan view of a small section of the improved board of this application, parts being broken to show the structure of the board.

Fig. 2 is an edge view of the section illus trated in Fig. 1.

Fig. 3 is a view similar to Fig. 2 showing the component parts of the board on an enlarged and exaggerated scale. the wire fabric being shown separated from the fibrous layers as before cementing and the application of pressure. to make the construction thereof clearer.

Fig. 4 is a view similar to Fig. 3 but showing a modification of the board shown in the latter figure.

Fig. 5 is a view similar to Fig. 4 showing a further modification.

Fig. 6 is a plan view of a finished panel for the door of an automobile showing one use to which the fiber board of this application may be put.

Fig. 7 is a cross sectional view on the line 7-7 of Fig. 6.

Like reference characters indicate like parts throughout the several figures.

My improved board is formed around a wire cloth or fabric 10 of relatively fine mesh. The fineness of the mesh will vary in accord ance with the use to which the board is to be put. In the manufacture of a board suitable for use in the fabrication of automobile trim panels. I have found that a cloth or fabric of #12 mesh is best adapted to produce a board having all parts thereof in a firm adherent contact at all points that will be maintained when the board is bent and under conis preferably ungalvanized and uncoated in any manner, so that the necessary firm union may be brought about between said fabric and the layers of fibrous material hereinafter referred to.

Preferably, a layer 11 of fibrous material such as paper is applied to one side of the wire cloth or fabric 10 and another layer 12 of fibrous material. such as paper, is applied to the other side of said cloth or fabric, thou h if desired, the wire cloth or fabric may Te embedded in paper pulp. Preferably, the paper layers 11 and 12 are manufactured of a multiplicity of laminations of kraft and chip paper. The inner laminations of each of these layers is essentially or almost entire- 1y chip, while the outer surface layer is essentially kraft, about 80% kraft paper for the lamination forming said surface being preferable. Paper manufactured in this way provides a relatively hard outer surface and a relatively soft and porous inner surface. In manufacturing the board of this application the soft and relatively porous surfaces of the layers 11 and 12 are disposed adjacent the wire cloth or fabric 10. Layers 11 and 12 preferably consist of 30% kraft and chip, though, as above indicated, the kraft paper is disposed adjacent the outer surfaces of the layers. Paper on the market at the present time, known as test-liner and used in the manufacture of shipping cases approved by the railroads, is an example of a commercial material suitable for use in the produ tion of the board of this application. In the rawings the variations in the characteristics of the layers 11 and 12 are shown, the numeral 13 indicating the relatively hard outer surface consisting essentially of kraft paper, while the numeral 14 has been used to designate the softer or chip interior surface.

Preferably, the fibrous material forming a part of the board of this application is made by the calendering cr cylinder process, rather than the FOUIdIlIllBI process. Paper manufactured in accordance with the first named process has a grain. I prefer to arrange the layers 11 and 12 so that the grain of the aper runs in the same direction, and I have ound that paper having a grain produces a more satisfactory board than paper manufactured in such a way that no grain is formed. If desired, however, the grain of the paper of the several layers may be disposed transversely to each other.

Layers 11 and 12 are combined to the wire cloth or fabric 10 and to each other by applying a flexible water-proof cement in sufficient quantity to cause firm adherence between the fibrous layers and the wire cloth. After the flexible water-proof cement has been applied the product is subjected, by calendering or otherwise, to sufficient pressure to cause the fibrous layers to firmly unite with JIH) the fabric and to each other th ough he m: in said fabric and to cause the release- 1y soft inner portions of the fibrous layers to enter the interstices in the metal cloth or fabric and thus be interlocked therewith. Preferably, suflicient pressure is exerted on the material so that the high portions of metal fabric are visible as slight protuberances on the surfaces of the completed material as shown in Fig. 1. Any suitable water-proof cement may be used to combine the layers. Casein, gelatins and substitutes, all known as glues, nitrocellulose or pyroxylin are suitable cements for this purpose. Flour or starch adhesives may also be used. If casein or any similar non-flexible cement is used it is desirable to add a small portion of a substance thereto to make it flexible. As an example of such a substance, glycerine is referred to, though other suitable substances having similar characteristics may be used. It has been found that unless the cement used is flexible, the adherence between the component parts of the board may not be maintained at all points when it is bent around curved or smiliar surfaces. By employing a flexible cement however, the material may be bent or even doubled Without danger of causing separation of the laminations thereof and without danger of rupture or weakening of the board.

I have found that in order to prevent warping of the board when exposed to moisture it is essential that the outer surfaces thereof be protected with a water-proof coating that serves to seal the relatively small pores in the hard outer surfaces of the fibrous material. Such a coating is applied to the outer surfaces of the layers 11 and 12 is Fig. 3 as indicated on the drawings.

A metal-reenforced fiber board including a wire cloth of #12 mesh and for the purpose above stated, is provided with layers 12 and 13 of paper of sutficient thickness to produce a .finished product having a thickness of .060". It should be understood however, that the thickness of the material and the mesh of the wire fabric will vary depending upon the use to which the product is to be put, so that the thickness just referred to is to be regarded simply as an example. The material of this thickness has been found to be suitable for use in the manufacture of the automobile trim panels as above stated.

' If it is desired the thickness of the board may be varied by increasing the thickness of the paper layers and the thickness of the wire fabric or even by multiplying the layers of metal cloth.

In the modification of the invention shown in Fig. 4 the metal-reenforced fiber board shown in Fig. 3 forms the foundation for a laminated material including an outer fabric finishing coating 15. The laminated structure shown in this figure is intended for use as a finish material for walls or similar surfaces and particularly for the interior of automobile bodies. The finishing covering 15 is applied to the layer 12 by a water-proof flexible cement of the character above referred to. In the manufacture of material in accordance with the disclosure in this figure it is unnecessary to provide the layer 12 with the water-proofin coating that is applied to the layer *11, b cause the waterproof cement that serves t unite the finishing covering to the lamin ted board serves this function. It will be understood that the finishing cover 1-5 may be drill, broadcloth. plush, mohair or any woven or similar fabric.

In Fig. 5 I have shown a further modification of the invention. In this figure the layers 11 and 12 of paper are not provided with the water-proof coating, but both of said layers are covered with a fabric material of any suitable kind, depending upon the use to which the product is to be put. As illustrated in this figure, the numeral 15 indicates a finishing covering fabric similar to the finishing fabric shown in- Fig. 4. This fabric is firmly united to the layer 12 by a flexible water-proof cement of the character above referred to. Said cement serves the function attributed to the cement coating referred to in connection with the description of the construction shown in Fig. 4. A fabric coating 16 is also applied to the layer 11. This cover may be a fabric of any character dependent upon the use to which the laminated board is to be put. The modification shown in this figure is intended for use when both surfaces of the laminated board are exposed and the covering may be selected in accordance with the characteristics that it is desired the outer layers should have. Opposite surfaces of the board may be provided with the same or different fabrics as may be deemed desirable.

In Figs. 6 and 7 I have illustrated one use to which the product of this invention may be put. In these figures the numeral 17 indicates a door panel for an automobile cut from a laminated board of the character shown in Fig. 3 or that shown in Fig. 4. Said panel is corrugated. as shown, for example, at 18. Said corrugation may be formed in any well known manner. The corrugation thus formed serves not only to enhance the appearance ofthe panel butit alsoserves tostiifen the panel as a whole. The corrugation may be formed in the material above described without weakening the same or without destroying the homogeneous character of the board. Attempts have been heretofore made to emboss or corrugate fibrous panels without practical success, because of the fact that the panel is weakened in forming the corrugations. I have found that it is entirely feas ible to corrugate or emboss the laminated material disclosed in this a plication in the manner illustrated in these figures or in any other equivalent manner, the material disclosed in this application may also be sewed if it is desired to attach to it any fabric material that can best be secured thereto by sewing. Such sewing does not weaken the laminated board. Or it may be tacked to a suitable foundation without weakening thereof due to penetration of the tacks.

The metal reenforced fiber board of this a plication has a strength far in excess of fiber boards at resent in common use. Said board is also 0 a very much lighter weight than an ordinary fiber board of the same degree of strength. Ordinarily, fiber board of the same thickness as the product disclosed in this application when subjected to a pop test on a Mullen tester will withstand only 160 lbs. per square inch. The metal reenforced fiber board of this application is able to withstand a pressure not in excess of 340 lbs. per square inch.

The invention may be embodied in other specific forms without departing from the s irit or essential characteristics thereof.

he present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.

What I claim as my invention is:

1. A metal reenforced fiber board suitable for use as a. flat or embossed panel consisting of a metal fabric of relatively small mesh, layers of fibrous material each having an outer hard surface applied to opposite sides of said fabric and cemented thereto and to each other to form a substantially homogeneous structure, said fibrous layers being pressed in the interstices of said fabric under pressure suflicient to cause the fibrous material'on 0pposite sides of said metal fabric to firmly unite through the small openings of said mesh to constitute a substantially homogeneous structure.

2. A-metal reenforced fiber board consisting of a metal fabric of relatively small mesh, layers of fibrous material applied to opposite sides of said fabric, each of said layers of fibrous material havin a relativel hard outer surface and a relatively soft surface adjacent said fabric, said fibrous layers being cemented to said fabric and to each other by a water-proof flexible cement to form a sub stantially integral structure and being united to said fabric under pressure so that the relatively soft portions of the fibrous material of said layers enters the interstices of said fabric and are cemented together through said interstices.

3. A metal reenforced fiber board consisting of an uncoated metal fabric of relatively small mesh, layers of paper material applied to opposite sides of said fabric, each of said layers of. paper material being formed to provide a hard outer surface and a relatively soft surface for contact with said fabric, said paper layers being cemented to said fabric and to each other by a flexible water-proof cement under suflicient pressure to form a substantially homogeneous structure in which the paper is interlocked with said fabric and cemented together through the interstices in said metal fabric.

4. A metal reenforced fiber board consisting of a metal fabric of relatively small mesh, layers of hard surfaced fibrous material having relatively soft inner surfaces applied to opposite sides of said fabric and cemented thereto and to each other to form a substantially homogeneous structure, the soft surfaces of said fibrous material being pressed in the interstices of said fabric, and a substantially water-proof coating sealing the external pores in the surfaces of said fibrous material applied to both sides of said board.

5. A metal reenforced fiber board consisting of a metal fabric of relatively small mesh, layers of hard surfaced fibrous material having relatively soft inner surfaces applied to opposite sides of said fabric and cemented thereto and to each other through the interstices of said fabric to form a substantially homo eneous structure, the soft surfaces of said fi rous layers being pressed through the interstices of said fabric and an outer layer of finishing cloth cemented to a side of said board by a. flexible water-proof cement.

6. A laminated board suitable for use as a flat or embossed panel comprising a metal .reenforced fibrous body having relatively hard outer surfaces and relatively soft inner portions in which the soft portions of the fibrous material and the metal reenforcement are united and interlocked so as to form a substantially homogeneous structure, and a covering of finishing material cemented to said body and covering a side thereof.

7. A panel for the body of a, vehicle or a similar purpose formed of a metal reenforced board consisting of metal fabric and fibrous layers of material having relatively hard outer surfaces and relatively soft inner surfaces applied to opposite sides of said fabric by a flexible water-proof cement, said layers being united to said fabric and to each other through the interstices of said fabric to form a substantially homogeneous structure. and a covering of finishing material cemented to the exterior of said panel, said panel being provided with stiffening elements pressed in said board, said covering material and its metal reinforcement.

WM. F. HAYES. 

